Method of selecting inkjet nozzle banks for assembly into an inkjet printhead

Abstract

A method of selecting inkjet nozzle banks for assembly into an inkjet printhead. The printhead when assembled includes at least two nozzle banks and is operative for printing one particular color ink or other liquid and each nozzle bank includes plural nozzles. The printhead is operational in a printer to print raster rows so that at least one raster row is printed using ink drops deposited at respective different pixel locations on the raster row by respective different nozzles on each of the at least two nozzle banks. The method includes (a) characterizing a drop size parameter for predetermined nozzles of each of the nozzle banks; (b) identifying for each of plural raster rows the respective different nozzles on each of the at least two nozzle banks that would be used to print the respective raster row; (c) identifying a size characteristic associated with each of the plural raster rows using a predetermined computer algorithm without printing the raster rows; and (d) determining in accordance with a criterion and data derived from size characteristic identified in step (c) whether or not the at least two nozzle banks are an acceptable match.

1 . A method of selecting inkjet nozzle banks for assembly into an inkjet printhead, the printhead when assembled including at least two nozzle banks and operative for printing one particular color ink or other liquid and each nozzle bank including plural nozzles, the method comprising the steps of: 
 (a) determining a drop size parameter(s) for the nozzles of each nozzle bank by examining printed lines or dots made by the respective nozzles of the respective nozzle bank, at least one of the nozzle banks including at least one defective nozzle; and    (b) after step (a), prior to assembly of the nozzle banks into an printhead, determining using a computer algorithm whether or not the at least two nozzle banks are an acceptable match that will allow all nozzles of each nozzle bank to be used for printing including the at least one defective nozzle.    
   
   
       2 . The method of  claim 1  and wherein a code is assigned relative to the characteristics of a nozzle bank in accordance with the determination made in step (a).  
   
   
       3 . The method of  claim 1  and wherein the at least two nozzle banks determined in step (b) to be an acceptable match are thereafter assembled in a printhead.  
   
   
       4 . An inkjet printhead assembled in accordance with the method of  claim 3 .  
   
   
       5 . A method of selecting recording element banks for assembly into a printhead, the printhead when assembled including at least two recording element banks and the banks being operative for printing raster rows wherein each bank includes plural recording elements and for at least some of the raster rows a recording element from each of the at least two recording element banks is used in printing pixels in the same raster row, the method comprising the steps of: 
 (a) determining a size parameter for the recording elements of each recording element bank by examining printed lines or dots or emissions made by the respective recording elements of the respective recording element bank; and    (b) after step (a), determining using a computer algorithm and without assembly of the recording element banks into a printhead as to whether or not the at least two recording element banks are an acceptable match that will allow all nozzles of each nozzle bank to be used for printing including one or more defective nozzles, wherein a simulated flat field image is considered in order to determine which recording elements would be used to print a respective raster row.    
   
   
       6 . The method according to  claim 5  and wherein in step (b) a size characteristic associated with each of the plural raster rows is identified.  
   
   
       7 . The method according to  claim 6  and wherein the size characteristic is average dot size for the respective raster row.  
   
   
       8 . The method according to  claim 6  and wherein the recording element banks are banks of inkjet nozzles and the printhead is an inkjet printhead.  
   
   
       9 . A printhead comprising at least two nozzle banks each bank having plural nozzles, the nozzle banks being assembled into the inkjet printhead after determining that they are an acceptable match in accordance with the method of  claim 8 .  
   
   
       10 . A method of selecting recording element banks for assembly into a printhead, the printhead when assembled including at least two recording element banks and the banks being operative for printing raster rows wherein each bank includes plural recording elements and for at least some of the raster rows a recording element from each of the at least two recording element banks is used in printing pixels in the same raster row, the method comprising the steps of: 
 (a) determining a size parameter for the recording elements of each recording element bank by examining printed lines or dots or emissions made by the respective recording elements of the respective recording element bank, at least on of the recording elements banks including a defective recording element; and    (b) after step (a), determining using a computer algorithm and prior to assembly of the recording element banks into a printhead whether the at least two recording element banks are an acceptable match such that all recording elements of each recording element bank including the at least one defective recording element are useable for printing.    
   
   
       11 . The method according to  claim 10  and wherein in step (b) a simulated flat field image is considered in order to determine which recording elements would be used to print a respective raster row.  
   
   
       12 . The method according to  claim 11  and wherein in step (b) a size characteristic associated with each of the plural raster rows is identified.  
   
   
       13 . The method according to  claim 11  and wherein the size characteristic is average dot size for the respective raster row.  
   
   
       14 . The method according to  claim 11  and wherein the recording element banks are banks of inkjet nozzles and the printhead is an inkjet printhead.  
   
   
       15 . A method of selecting inkjet nozzle banks for assembly into an inkjet printhead, the printhead when assembled including at least two nozzle banks and operative for printing one particular color ink or other liquid and each nozzle bank including plural nozzles, the method comprising the steps of: 
 (a) determining a drop size parameter(s) for the nozzles of each nozzle bank by examining printed lines or dots made by the respective nozzles of the respective nozzle bank, at least one of the nozzle banks including at least one defective nozzle; and    (b) after step (a), matching the at least two nozzle banks using a computer algorithm prior to assembly of the at least two nozzle banks into a printhead, such that when the at least two nozzle banks are assembled into a printhead all nozzles of each nozzle bank are useable for printing including the at least one defective nozzles.    
   
   
       16 . A method of selecting inkjet nozzle banks for assembly into an inkjet printhead, the printhead when assembled including at least two nozzle banks and operative for printing one particular color ink or other liquid and each nozzle bank including plural nozzles, the method comprising the steps of: 
 (a) determining a drop size parameter(s) for the nozzles of each nozzle bank by examining printed lines or dots made by the respective nozzles of the respective nozzle bank, at least one of the nozzle banks including at least one defective nozzle;    (b) after step (a), selecting the at least two nozzle banks using a computer algorithm and prior to assembly of the at least two nozzle banks into a printhead, such that when the at least two nozzle banks are assembled into a printhead, all nozzles of each of the at least two nozzle banks are useable for printing including the at least one defective nozzles; and    (c) assembling the selected at least two nozzle banks into a printhead.